Casting arrangement



y 3, 1950 'R. T. LEISK 2,509,154

CASTING ARRANGEMENT Filed Jan. 25, 1947 3 Sheets-Sheet 1 i .J v

IN VEN TOR.

May 23, 1950 1-, LElsK v 2,509,154

CASTING ARRANGEMENT Filed Jan. 25, 1947 3 Sheets-Sheet 2 May 23, 1950 R.T. ILEISK 2,509,154

' CASTING ARRANGEMENT Fiied Jan. 25, 1947 3 Sheets-Sheet 3 IN V EN TOR.

Q jg zzuwacy Patented May 23, 1950 CASTING ARRANGEMENT R lan '1. Lei k,East Louis, 1 1-, ass gns)! to American te l ou d s, fl ees 1 .1,, acerrora ioh f ew Jer y Application January 25, 1e44, Serial h 724,425

4, Cla ms.

This invention relates to the casting of metal and more particularly tothe production of ferrous castings.

,In the production of ferrous castings, such as axle housingsforlocomotive tender trucks and passenger car trucks, wherein unusuallylar e a e of e ta ting mus be d y m t n metal to prevent shrinkagecavities, it has been necessary according to the practices of the priorart to utilize large risers and connected Dads dis.- re d arou d h se ios o be ed- A e e t, ca in Of t i y e ha be f rmed wi large heads and pds urroun in th po ti n o he c s in to b fed. F r ex mple. axle housieastinss h be n on en i na ly eas wi h imme e ri e s an p ds nte r y conec d o the r ser an o th bel -s a ed nds of the eas nss This s rplusmet t eth h the a s. fr flu nt w gh d as mueh or mo e t a the fini hedcas n thus affording a ield of bout 40% in view of melting and foundrylosses. Furtherx ore v n i u inal h inka of suc cast ings has tended toproduce hot tears at the throats formed by the junct e f he inte mediateportion of the casting with the bellshap d ends ereo inasmu h as the rse a d padding around these end resisted shrinkage in the molding sand,as hereinafter discussed. This tendency to tearing has been customarilyavoided by the use of chills in the throat at each end of the casting.

Accordingly, it is a primary object of the pres.- ent invention toprovide a novel method and means for economically producing ferrousmetal casting and increasing yields in the production of such castings.Another object of the invention is to provide a novel method and meansfor reducing the size of the riser and padding around castings such asabove described.

Another object of the invention is to reduce finishing costs byeliminating integral padding around the casting.

Another object of the invention is to provide a novel method and meansfor eliminating hot tea-rs in elongated castings with risers at the endsthereof.

Another object of the invention is to eliminate the necessity for chillsin the throats of elongated castings with e larged portions which mustbe fed by associated risers. s i l n h o ect f h enti n is to pr d a nvel method and means. for h atin a section of a casting 1 be fed Withariser while the m l n metal ows rom h riser in o t sec io to eve t sh ik g avities the e nst l no he ob ect f the. in ent on s o pr duce soundcast g h be ter surfac cond t ons, the eby reducing e amount of m h finsh The foregoing and other object and advantages of the invention willbecome apparent from a consideration of the following specification andthe accompanying drawings wherein:

Figural is a fragmentary plan view of the drag of a conventional sandmold with the casting- -therein partlyshown in section along the lineI--l of Figure 2 to disclose the central core, a portion of which isbroken away;

Figure 2 is a vertical cross-sectional view through the mold takenonthe-line 2-2 of Figure :1 with the casting and" cores shown in elevation Figure 3. isa fragmentary longitudinal section through the moldat the gate side of the casting which is shown inelevation;

Figure. 4,is..a perspectiveview of the unfinished casting after it hasbeen removed fromthemold;

Figure 5 is a perspective viewof the finished casting;

Figure 6 is. a. fragmentaryiplan view similar to Figure 1 illustrating amodification of the invention, thev casting being partly shown insection along the line 6-6 of Figure-7;

Figure 7 is a fragmentary sectional view corresponding to: Figur 2. butillustrating the modification of Figure 6;

Figure 8 isa, fragmentary lnn itudinalsectional view eorreependihs to.Fi ure 3 but illustr tin the mod fi at on oi F -u e 6; and

Fi ures 9 and l a s ectively a fra men a y s de, evation an alreshienter end view ti he nes hown in Fi ures -8 ith the sates h e eh awy a d the co es emoved- Referring first to Figures 1-5, the; inventionis llus ted a a ied to n axle housin a ine g neral y d g t lend omp i n11 1- ewelonee e tu ul r or ion-.4 wi h e be lheree end o h B at e ch etremi the e Th c s n s show n igu s 1- i ha ate 8. runn rs 0 and p eslco e ti g ea h unner ill to the associated hub 6. Each of the hubs isconnected bya neck l4 to an open riser l5 have ing heating pad, portions18,- disposed around the 111 b 6 and spaced therefrom by a ring core 20.T r 201. e e ably rm dei 1 1 se men s, two of which are indicated at 22:and inthe drag. 6 o the o d and th eere-ihd e t d 3& and ,2 h-the:s Pe.34; as best his:

ure 2. The center segment 36 of the cope portion of the core ipreferably pasted to the segments 28 and 32 and is provided with asuitable opening accommodating the neck 14 of the riser.

A center core, generally designated 36, is also provided and ispreferably formed in two halves pasted or doweled together in the usualmanher. The core 36 is preferably supported at its ends in the moldingsand of the drag and is provided with a longitudinal vent 38 formed bymatching grooves in the adjacent faces of the two halves of the core 36.

It may be noted, as best seen in Figures 2 and 3, that the partin lineof the cope and drag portions of the mold is in the horizontal planecoinciding with the line ll of Figure 2; and the longitudinal axis ofthe casting cavity in which the casting 2 is formed lies substantiallyin the plane of the parting line.

In pouring the casting, the molten metal flows from the gate 6 throughthe runners in and into the sprues l2 and thence into the mold cavity toform the casting 2. The molten metal flows upwardly through the necks l4to form the risers l6 and heating pads l8. As the molten metal coolswithin the mold, each hub section 6 is fed with molten metal from theassociated riser 16 through its neck (4 to prevent shrinkage cavities inthis section. The hub section is heated at this time by the pads 18 tofacilitate feeding of the entire hub section as the casting solidifies.The finished casting is formed by breaking or burning off the necks l4and the sprues l2, and the casting is then ground to the desired finishas shown in Figure 5.

It may be noted that according to prior art practices which have beenutilized for years, the riser l6 and pads I8 have been cast integralwith the hub sections 6, thereby forming immense ends on the casting.These ends have reduced the metal yield and have increased finishingcosts by necessitating burning and grinding of the entire hub section.Furthermore, longitudinal shrinkage of the casting tended to produce hottears in the throats of the casting, indicated at 46, at the juncture ofthe hub portions 6 with the intermediate portion 4, therebynecessitating the use of chills in the mold to prevent hot tears atthese points.

According to the present invention, however, these chills have beensuccessfully eliminated inasmuch as the relatively small riser necksyield against the thrust of the molding sand thereby reducing stressesin the throats as the casting shrinks. Thus castings of this type havebeen successfully produced with a lower percentage of defective castingsand at much lower cost than in accordance with the prior art practiceswhich have long been regarded as preferred techniques in this art.

Referring now to Figures 6-10, a modification of the invention is shownwherein certain additional advantages are achieved. In this embodimentof the invention each riser 52 is connected to the hub section of thecasting 54 through a neck 56 extending through a complementary openingin a core 58 which is formed as a complete ring preferably having twodrag segments 66 and 62 and three cope segments 64, 66 and 6B. In thisembodiment, the riser 52 is a blind riser, and preferably a green sandcore lfl projects into the top of the riser to afford a V notch, as seenin Figure 8. This notch permits atmospheric pressure to rupture the topsurface of the metal within the riser 52, thereby facilitating feedingof molten metal therefrom to the casting 54, as will be readilyunderstood by those skilled in the art.

It may also be noted that in the embodiment of Figures 6-10 the heatingpads 12 are reduced in width and are disconnected from the riser 52 sothat molten metal flows from the gate 14 into the runner l6 and thencefrom three sprues I8, and 82 into the heating pads 72 and into the hubsection of the casting 54. In this connection, it will be seen from aconsideration of Figures 8 and 9 that the sprue 86 through which metalenters the heating pad cavity is at the lowest point within the moldbeneath the level of the sprues I8 and 82. Thus any loose sand which maybe washed from the gate of the mold enters the sprue 80, therebyinsuring that such sand enters the heating pad 12 rather than thecasting 54. Furthermore, in the embodiment of Figures 6-10, the riser 52is disconnected from the pad I2 so that the metal within the riser isnot utilized to feed the pads. This arrangement permits a considerablereduction in the size of the riser.

Another advantage of the modification of Figures 6-10 may be noted inthat the metal enters the heating pad cavities at substantially the samerate as the casting cavity within which the casting 54 is formed. Thusthe ring core is relieved of stresses which result when the castingcavity is filled first so that the ring core temporarily supports theweight of the metal within the hub portion of the casting cavity.

It will be understood that as the casting solidifies it is fed withmolten metal through the neck 56 of the riser 52, the pads I2 beingeffective to heat the hub section of the casting so that the same coolsgradually at this time, thus accommodating the feeding of the metal fromthe riser into the casting. As above-mentioned, atmospheric pressureruptures the top surface of the metal within the riser 52 so thatatmospheric pressure on the molten metal therewithin facilitates feedingof the casting. After the casting and riser 52 have completelysolidified, as seen in Figures 9 and 10, the riser contains a shrinkagecavity, indicated at 84 from which the molten metal has been fed intothe casting.

It may be noted that the invention has been described with respect tothe casting of an axle housing; however, the invention is equallyapplicable to other types of castings wherein it is desired to feedunusually large sections or where it is desired to feed an isolatedsection of the casting without the use of an extra riser.

It is to be understood that I do not wish to be limited by the exactembodiments of the device shown which are merely by way of illustrationand not limitation as various and other forms of the device will, ofcourse, be apparent to those skilled in the art without departing fromthe spirit of the invention or the scope of the claims.

I claim:

1. In means for supplying molten metal to feed shrinkage in asolidifying casting, the combination with a mold having a casting cavityand a communicating reservoir for molten feed metal, of a heating padcavity adjacent to and spaced from the section of said casting cavitycommunicating with said reservoir, a gate having a connection to saidcasting cavity, said pad cavity being connected to said reservoir andextending downwardly from opposite sides thereof below the level of saidconnection and substantially surrounding the casting cavity.

2. A mold comprising a casting cavity having a section to be fed by ariser of molten metal, a riser cavity in said mold above said sectionand adapted to contain said riser, a pair of heating pad cavitiesconnected at their upper ends to said riser cavity and extendingdownwardly around said section to a point below the lowest point of saidsection, a heat permeable sand core spacing said pad cavities from saidsection, said core having a smaller cross-sectional area than that ofeach pad, and passage means through said mold for delivering moltenmetal to at least one of said cavities at a point above the lowerextremities of said pad cavities.

3. A metal casting mold comprising a top cope section and a bottom dragsection containing a casting cavity and having a partin line along aplane substantially on the longitudinal axis of the cavity, anon-metallic core substantially annular in form and supported in saiddrag section as a separable unit substantially encircling a portion ofsaid cavity, another core extending through said cavity and supported insaid drag section whereby the cores define an annular section of thecasting cavity, a riser cavity in the cope portion above said annularsection and connected thereto through an opening in the firstmentionedcore, heating pad cavities connected to opposite sides of the risercavity and extending through both mold sections and substantiallyencircling the first-mentioned core, and a gate having a connection tosaid annular section at a point below said plane and above the lowestlevel of said pad cavities whereby feeding of the cooling metal in saidannular section by the metal in said riser cavity is ensured.

4. A metal casting mold comprising a top cope section and a bottom dragsection containing a casting cavity and having a parting line along asubstantially horizontal plane passing through the cavity, a risercavity connected to the top of the casting cavity, a gate connected tothe casting cavity in the drag section at spaced points disposed atopposite sides of a substantially vertical plane passing through saidcasting cavity, and a heating pad cavity extending upwardly from belowsaid points to at least the level of the connection between the riserand casting cavities, said heating pad cavity being spaced asubstantially uniform distance throughout its circumference from saidcasting cavity and said heating pad cavity being connected to one ofsaid riser and casting cavities.

ROLAND T. LEISK.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,456,855 Midgley May 29, 19231,572,428 Grimes Feb. 9, 1926 1,678,655 Sipp July 31, 1928 1,716,833Rich June 11, 1929 1,828,271 Arnold Oct. 20, 1931 1,938,707 Mann Dec.12, 1933 2,313,517 Cameron Mar. 9, 1943 2,431,879 Mebs Dec. 2, 1947

